Reinforced smart mud pump

ABSTRACT

A pump system for movement of fluids having a reciprocating piston power pump having at least three reciprocating pistons operable to displace fluid from a housing having a pumping chamber, an integrally forged crankshaft operably connected to the pistons, at least one sensor operable to sense ambient conditions on the pump, and a computer control for processing data from the sensor to regulate the operation of the pump in response to the data. The system also utilizes protective infused treatments for lubricity and enhanced lubrication sprayers and a reset relief valve and pressure sensors operably connected to the computer system for control and monitoring of the pump.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is related to a provisional application for patentfiled Jul. 30, 2007 bearing Ser. No. 60/962,637 and is incorporated byreference herein as if fully set forth.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

DESCRIPTION OF ATTACHED APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

This invention relates generally to the field of mud pumps and morespecifically to a reinforced smart mud pump. Mud pumps that use pistondisplacement, produce imposed forces that cause wear and tear on variouspump components, including pump cross head piping, cylinders, inlet anddischarge valves, seal components including piston or plunger seals, thepump cylinder block or so-called fluid end, and other components. Therehas been a need to provide increased longevity and performance for suchpumps and to determine if deteriorations in pump performance areoccurring, to analyze the source of decreased performance and to furtherreal time control and data to monitor and in some cases change theoperating characteristics before damage occurs to the pump. The use ofgreatly strengthened components in combination with a computercontrolled system integrated with a real time monitored and controlledreset relief valve may be integrated into an oilfield application toprevent catastrophic pump failure and extend pump life.

Pump operating characteristics often have a deleterious effect on pumpperformance. For example, delayed valve closing and sealing can resultin loss of volumetric efficiency. Factors affecting pump valveperformance include fluid properties, valve spring design and fatiguelife, valve design and the design of the cylinder or fluid end housing.Delayed valve response also causes a higher pump chamber pressure thannormal which in turn may cause overloads on pump mechanical components,including the pump crankshaft or eccentric and its bearings, speedreduction gearing, the pump drive shaft and the pump prime mover.Moreover, increased fluid acceleration induced pressure “spikes” in thepump suction and discharge flowstreams can be deleterious. Fluidproperties are also subject to analysis to determine compressibility,the existence of entrained gases in the pump fluid stream,susceptibility to cavitation and the affect of pump cylinder or fluidend design on fluid properties and vice versa.

Still further, piston or plunger seal or packing leaking can result inincreased delay of pump discharge valve opening with increased hydraulicflow and acceleration induced hydraulic forces imposed on the pump andits discharge piping. Moreover, proper sizing and setup of pulsationcontrol equipment is important to the efficiency and long life of a pumpsystem. Pulsation control equipment location and type can also affectpump performance as well as the piping system connected to the pump

In prior art, the control of a mud pump has been disclosed focused onpiston position for acquiring information about the pump and itsperformance characteristics. For example, U.S. Pat. No. 6,882,960 toMiller, shows a system for monitoring and analyzing performanceparameters of reciprocating piston, or power pumps and associated pipingsystems. This patent fails to disclose the innovative aspects of thepresent invention.

Nothing in the prior art shows a computer integrated mud pump withsignificant strengthening features that increase the life cycle of apump in the manner of the present invention with real time control ofsignificant operating functions and feedback from various sensors andreset relief valves.

BRIEF SUMMARY OF THE INVENTION

The primary advantage of the invention is to provide a mud pump that iscontinuously monitored during operation.

Another advantage of the invention is to provide a mud pump thatutilizes transducers in line with the ambient pressure in conjunctionwith a computer controlled pressure relief valve to record and monitorpump characteristics and control the pump to prevent catastrophicfailure.

Another advantage of the invention is to provide a mud pump thattransmits data to a computer for later analysis of important operatingcharacteristics.

A further advantage of the invention is to provide a mud pump that canbe controlled during its operation to prevent certain damaging events tothe pump or underlying pressurized system.

Yet another advantage of the invention is to provide a single pieceintegrally forged and balanced crank assembly for greater strengthduring operation.

Still yet another advantage of the invention is to provide increasedtensile strength up to 200,000 p.s.i. using advanced metallurgicalengineering.

In accordance with a preferred embodiment of the invention, there isshown a pump system for movement of fluids having a reciprocating pistonpower pump having at least three reciprocating pistons operable todisplace fluid from a housing having a pumping chamber, an integrallyforged crankshaft operably connected to the pistons, at least one sensoroperable to sense ambient conditions on the pump, and a computer controlfor processing data from the sensor to regulate the operation of thepump in response to the data.

In accordance with a preferred embodiment of the invention, there isshown a pump system for movement of fluids having a reciprocating pistonpower pump having at least three reciprocating pistons operable todisplace fluid from a housing having a pumping chamber, an integrallyforged crankshaft operably connected to the pistons, polyflorocarboninfused treatment applied to at least one crosshead and one crossheadslide in the system, and at least one sensor operable to sense ambientconditions on the pump.

In accordance with a preferred embodiment of the invention, there isshown a pump system for movement of fluids having a reciprocating pistonpower pump having at least three reciprocating pistons operable todisplace fluid from a housing having a pumping chamber, an integrallyforged crankshaft operably connected to the pistons, at least one sensoroperable to sense ambient conditions on the pump, a computer control forprocessing data from the sensor to regulate the operation of the pump inresponse to the data; and pressure sensors for monitoring fluid pressureoperably connected to the computer control. In addition, upper and lowerlimits to temperature, vibration and pressure can be set. Further, in apreferred embodiment, all lubrication and water pumps must be on beforethe control system will permit unit to be operated.

Other advantages of the present invention will become apparent from thefollowing descriptions, taken in connection with the accompanyingdrawings, wherein, by way of illustration and example, an embodiment ofthe present invention is disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings constitute a part of this specification and includeexemplary embodiments to the invention, which may be embodied in variousforms. It is to be understood that in some instances various aspects ofthe invention may be shown exaggerated or enlarged to facilitate anunderstanding of the invention.

FIG. 1 shows a side view of the pump and auxiliary equipment accordingto a preferred embodiment of the invention.

FIG. 2 shows a side view of the pump internal forged crank and plungerconnections according to a preferred embodiment of the invention.

FIG. 3 shows a partial cutaway side view of the pump according to apreferred embodiment of the invention.

FIG. 3A shows a cross sectional view of the positive air pressureplunger seal about a synchronized plunger rod according to a preferredembodiment of the invention.

FIG. 4 shows a partial cutaway overhead of the pump housing according toa preferred embodiment of the invention.

FIG. 4A shows a schematic drawing of a representative computercontrolled monitoring system according to a preferred embodiment of theinvention.

FIG. 5 shows a perspective view of the pressure relief valve accordingto a preferred embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Detailed descriptions of the preferred embodiment are provided herein.It is to be understood, however, that the present invention may beembodied in various forms. Therefore, specific details disclosed hereinare not to be interpreted as limiting, but rather as a basis for theclaims and as a representative basis for teaching one skilled in the artto employ the present invention in virtually any appropriately detailedsystem, structure or manner.

In a preferred embodiment of the present invention, there is shown areciprocating plunger or piston power pump. The pump includes additionalfeatures not found in conventional reciprocal pumps as heretoforedescribed. The basic operation of the pump is similar to a triplexplunger pump configured to reciprocate three spaced apart plungers orpistons, which are connected by suitable connecting rod and crossheadmechanisms, to a rotatable crankshaft or eccentric. FIG. 1 shows a sideview of the pump and auxiliary equipment according to a preferredembodiment of the invention. Pump housing 100 covers the internal pumpcomponents and allows for a variety of conventional means to move therotatable crankshaft 114 such as an electric motor 102 and belt drive104. Within pump housing 100 may be disposed a pressurized lubricationspraying system that continuously feeds lubricant such as oil around thecrankshaft and associated internal pump components.

A suction module 104 of conventional design houses each plunger whichoperates each section of the triplex plunger pump. A pressure reliefvalve mount 110 allows for attachment of a reset relief valve (show inFIG. 5) to at least one suction module 106 in a system for pumpingdrilling mud composed of water, clay and chemical additives, downthrough the inside of a drill pipe of an oil well drilling operation.The drilling mud is pumped at very high pressure so the mud is forcedout through a bit at the lower end of the drill pipe and returned to thesurface, carrying rock cuttings from the well. In this illustrativeexample the drilling mud from the pump system is fed into the attachedvessel 112 sometimes known as a dumping ball. In a preferred embodimentall components are installed on a full unitized skid 120 providing roomfor motors, starters, sheaves, belts and any associated test equipmentand a solid platform for installation of bracing 122 for componentparts. Vessel 112 smoothes out the pulsation caused by the pumpingaction of the system to deliver pumped fluid out of port 115 in a morecontrolled manner.

With the use of computer modeling, high technology engineering,metallurgical and mechanical enhancements, the smart pump isrevolutionary in design. The pump is manufactured using advancedmaterials and techniques including an integrally forged and balancedcrank. This provides significant strength advantages and increases thelife cycle of the pump. Unlike prior art pump systems, the crank is nota porous unbalanced crank casting, nor is it a fabricated with separateplates and bars and later welded together. As shown in FIG. 2 the crank200 is fabricated from an integrally forged single ingot by the openhammer forging process resulting in a single piece with no welding orpinning of multiple pieces. A connecting rod 202 for each plunger isattached to the crank 200 such that the crank freely rotates and createsa reciprocating action in each connecting rod 202 attached to the crank200. A crosshead 204 and crosshead slide 206 attach to each connectorrod to help retain engine oil in the crankcase. A plunger connection 210at each connector rod 202 end provides a means of attachment for avariety of rod and plunger components.

All of the ground crossheads 204 and honed crosshead slides 206 aretreated with a polyflorocarbon coating for more lubricity and wearperformance characteristics resulting in 15% less energy cost. Thisprocess has been used in the racing industry with much higherperformance results. The poly-fluorocarbon coating is applied to eachcrosshead and slide and helps retain engine oil on the componentsurfaces during intense heat and extreme pressure. The oil isessentially absorbed into each crosshead 204 and slide 206 in such a wayas to increase their lubricity. The crosshead 204 center line alignmentis laser monitored for even wear. In a preferred embodiment of theinvention the pump uses suction modules, discharge modules and dischargemanifold and a double helical gear set. All gear sets are prepared withmesh test providing contact tapes accompanied by digitals to AGMS 11+standards. All gear sets are further preferably chemically treated to0.4 RMS or better to exponentially increase bearing life.

In the present invention, the crankshaft is a integrally forged piece toincrease its operating strength significantly, and is an integral partof the crank 200. The terms crank 200 and crankshaft are usedinterchangably although in conventional pumps and engines the crank 200and crankshaft may comprise separate components. Turning again to FIG. 1we see the crankshaft includes a rotatable input shaft portion adaptedto be operably connected to a suitable prime mover, such as an internalcombustion engine or electric motor 102, as an exemplary installation.The crankshaft is mounted in a suitable, so-called power end housing 114which is connected to a fluid end structure configured to have aplurality of pumping chambers, in this example, three separate pumpingchambers exposed to their respective plungers or pistons. Plungers referto the rod, rod joints and piston end portions of the plunger unlessotherwise specified.

FIG. 3 shows a partial cutaway side view of the pump according to apreferred embodiment of the invention. The fluid end comprises a housinghaving the series of plural cavities or chambers for receiving fluidfrom an inlet manifold by way of conventional poppet type inlet orsuction valves contained each suction module 300. The piston or plunger304 projects at one end into the chamber and is connected to a suitablecrosshead mechanism 306, including a crosshead extension. The crossheadextension is operably connected to the crankshaft using connecting rods308 as described above. Each plunger 306 projects through a conventionalpacking 310 or plunger 306 seal. Each chamber for each plunger 306 isoperably connected to a discharge piping manifold by way of a suitabledischarge valve. Valves may be of a variety of conventional designs andare typically spring biased to their closed positions. Valves may alsoinclude or are associated with removable valve seat members. Each valvemay also have a seal member formed thereon engageable with theassociated valve seat to provide fluid sealing when the valves are intheir respective closed and seat engaging positions. A unique feature ofa preferred embodiment of the smart pump is a positive air pressureplunger seal 312 to prevent leakage and prevent wear on the plunger.FIG. 3A shows a cross sectional view of the positive air pressureplunger seal about a synchronized plunger according to a preferredembodiment of the invention. As the plunger 350 moves reciprocally,pressurized air is introduced into through seal 352 through a pluralityof pressurized air ports 354 preventing fluid leakage from the plunger350 end which engages and moves drilling mud through the aforementionedvalves. The pressurized air flow 356 isolates any material from scoringand etching the plunger 350 and reduces friction between the seal walland the plunger 350.

In a preferred embodiment the pump may be fitted with a P-QUIP® fluidend systems including P-QUIP® kwik clamp liner retentions system,P-QUIP® kwik rod system and cover system. The P-QUIP® kwik-clamp valveand strainer cover retention system has a very fast and safe access withmuch reduced down time and LTAs (Lost Time Accidents) due to mishaps.Hammers or cheater bars are not required and the system includes anautomatic clamping means which results in no more under or overtightening—caps will not loosen off in use. This all results in easyinstallation and easy operation with conventional air or hand operatedhydraulic pump. Like the Liner Retention System, the valve and strainercovers are sealed firmly in the fluid end by means of a springmechanism. Similarly, the outer cover is removed when the clamping forceis released by means of the hydraulic pump. This system heightens safetyas it is no longer necessary to tighten OEM type threaded cap retainersby hammer.

The P-QUIP® kwik rod system allows for fast and safe piston changes andis constructed of 17.4 PH martensitic high-resistance stainless steel,eliminating corrosion. Three piece rod system is held together usingpins, which eliminates prior systems and clamp type systems. The P-QUIP®kwik cover system allows for fast and save valve access changes with nohammers or cheater bars. The cover offers a positive retention forceagainst the plug eliminating the need for retightening. The P-Quip® kwikrod pump rod system permits fast and safe piston changes resulting inreduced down time. There is no need for heavy clamps or connectingthreads and studs. The clamping force is automatically controlledresulting in no broken rod ends. Due to its construction, its selfalignment facility gives improved piston and liner life. There are nocorrosion problems as all parts are stainless steel, includinghard-surfaced stainless steel power end rods. It has an integral linerflushing systems.

On conventional mud-pump rod systems, the rod is held together by meansof taper clamps and screw threads which are slow and awkward to assemblecorrectly and readily wear out. Due to their design, the clamps obscurevision of the rod joints, preventing a check being made that the rod iscorrectly aligned. Uneven loads are imposed on the flanged rod ends,resulting in premature failure.

The P-QUIP® Kwik-Rod system avoids these problems as the rod componentsare held together by powerful spring-loaded ends on a release link inthe center of the rod assembly. The ends of the release link areattached to the pony rod and piston rod by means of high tensilestainless steel pins held in shear. The shear force is very quickly andeasily released by a few strokes of a small hydraulic pump.

Dismantling and re-assembly of the complete rod system takes under oneminute. Furthermore, there are no flanged joints on the rods to chip,wear or break. Hence, rod life is enhanced and, because rod alignment isreadily achieved, significantly improved swab and liner life isgenerally obtained. FIG. 4 shows a partial cutaway overhead of the pumphousing according to a preferred embodiment of the invention. Plungerrods 400 are synchronized based on the crank speed and can be checkedfor alignment as described herein. In a preferred embodiment, a viewingport 402 or access cover allows access to plunger rods 400 for alignmentand maintenance.

Further enhancement to the pump is achieved by use of ductile iron forthe crossheads, the crosshead slides and the connecting rods. Theconnecting rods are solid ductile iron which reduces their elongationduring setoff to zero. The typical rod experiences stretching orelongation during set-off when the relief valve is activated. Thebenefit of ductile iron in increased strength and higher tensilestrength. All the major components, the crank, the crossheads, theslides and the rods by use of mettalurgical engineering are designed tobring the pump tensile strength up to 200,000 p.s.i.

The pump is network and web based with a data acquisition system tomonitor pump performance and constantly evaluate pump valve dynamics.Pressure transducers are located in pump chambers used to determinevalve sealing delays, fluid compression delays, chamber overshootpressure, crosshead loading shock forces and chamber volumetricefficiency. Pressure transducers are also located in suction piping andmanifolds and discharge piping and manifold. Temperature is similarlymonitored for fluid temperature for mud properties and power endlubrication. Further, there is real time power input data to calculatesystem mechanical efficiency.

Those skilled in the art will recognize that the present invention maybe utilized with a wide variety of single and multi-cylinderreciprocating piston power pumps as well as possibly other types ofpositive displacement pumps. However, the system and method of theinvention are particularly useful for analysis of reciprocating pistonor plunger type pumps. Moreover, the number of cylinders of such pumpsmay vary substantially between a single cylinder and essentially anynumber of cylinders or separate pumping chambers and the illustration ofa so called triplex or three cylinder pump is exemplary.

The performance analysis system of the invention is characterized, inpart, by a digital signal processor which is operably connected to aplurality of sensors via suitable conductor means well known in the art.The processor may be of a type commercially available as previouslydescribed and may wireless remote and other control options associatedtherewith. The processor is operable to receive signals from a powerinput sensor which may comprise a torque meter or other type of powerinput sensor. Power end crankcase oil temperature may be measured by asensor. Crankshaft and piston position may be measured by anon-intrusive sensor including a beam interrupter mountable on a pumpcrosshead extension for interrupting a light beam provided by a suitablelight source or optical switch.

A vibration sensor may be mounted on the power end or on the dischargepiping or manifold for sensing vibrations generated by the pump.Suitable pressure sensors are adapted to sense pressures at numerouslocations, including the inlet piping and manifolds. Other pressuresensors may sense pressures in the pumping chambers of the respectiveplungers or pistons. Other pressure sensors sense pressures upstream anddownstream of a discharge pulsation dampener. Still further, a fluidtemperature sensor may be mounted on discharge manifold or piping tosense the discharge temperature of the working fluid. Fluid temperaturemay also be sensed at the inlet or suction manifold.

Pump performance analysis using the system may require all or part ofthe sensors described above, as those skilled in the art will understandand appreciate from the description which follows. The processor may beconnected to a terminal or further processor, including a display unitor monitor mounted in a housing connected to the pump system and mainhousing. Still further, the processor may be connected to a signaltransmitting network, such as the Internet, or a local network.

FIG. 4A shows a schematic drawing of a representative computercontrolled monitoring system. A computer 450 receives input from sensors452 and modules 454 in the pump system and uses software algorithms toanalyze pump performance, record and display operational data on avisual screen display 456. The computer controlled monitoring system maybe adapted to provide a wide array of graphic displays and dataassociated with the performance of a power pump on a real time or replaybasis. A substantial amount of information is available including pumpidentification (Pump ID) crankshaft speed, fluid flow rate, time lapsesince the beginning of the display, starting date and starting time andscan rate. The display 456 displays discharge piping operating pressure,peak-to-peak pressures, fluid flow rate induced peak-to-peak pressure,fluid flow induced peak-to-peak pressure as a percentage of averageoperating pressure, pump volumetric efficiency and pump mechanicalefficiency. The display 456 also indicates discharge valve seal delay indegrees of rotation of the crankshaft from a so called piston zero ortop dead center (maximum displacement) starting point with respect tothe respective cylinder chambers of the pump, as well as piston sealpressure variation during fluid compression and suction valve seal delayin degrees of rotation of the crankshaft or eccentric from the top deadcenter position of the respective cylinder chambers. Still further, thepump type may be displayed as well as suction piping pressures, asindicated. The parameters displayed are determined by the system of theinvention which utilizes the various sensors.

Various pressure sensors 452 sense pressure in the respective pumpchambers associated with each of the pistons and pressure signals aretransmitted to the processor. These pressure signals may indicate whenvalves are opening and closing. For example, if the pressure sensed in apump chamber does not rise essentially instantly, after the piston forthat chamber passes bottom dead center by 0 degrees to 10 degrees ofcrankshaft rotation, then it is indicated that the inlet or suctionvalve is delayed in closing or is leaking. In situations like this, thedisplay may show that a discharge valve is not closed for 16.7 degreesof rotation after piston top dead center position. Accordingly, pressurechanges, or the lack thereof, are sensed by cylinder chamber pressuresensors.

Software embedded in the computer 450 processor is operable to correlatethe angle of rotation of the crankshaft with respect to pressure sensedin the respective cylinder chambers to determine any delay in pressurechanges which could be attributable to delays in the respective suctionor discharge valves reaching their fully seated and sealed positions.These delays can, of course, affect volumetric efficiency of therespective cylinder chambers and the overall volumetric efficiency ofthe pump. In this regard, total volumetric efficiency is determined bycalculating the average volumetric efficiency based on the angular delayin chamber pressure increase or pressure decrease, as the case may be,with respect to the position of the pistons in the respective chambers.

The volumetric efficiency of the pump is a combination of normal pumptimed events and the sealing condition of the piston seal and the inletand discharge valves. Pump volumetric efficiency and component status isdetermined by determining the condition of the components andcalculating the degree of fluid bypass. Pump volumetric efficiency (VE)is computed by performing a computational fluid material balance aroundeach pump chamber.

Pump chamber pressures, as sensed by the sensors may be used todetermine pump timing events that affect performance, such as volumetricefficiency, and chamber maximum and minimum pressures, as well as fluidcompression delays. Still further, fluid pressures in the pump chambersmay be sensed during a discharge stroke to determine, through variationsin pressure, whether or not there is leakage of a piston packing orseal, such as the packing seal. Still further, maximum and minimumchamber fluid pressures may be used to determine fatigue limits forcertain components of a pump, such as the fluid end housing, the valvesand virtually any component that is subject to cyclic stresses inducedby changes in pressure in the pump chambers and the pump dischargepiping.

As mentioned previously, the computer 450 processor may be adapted witha suitable computer program to provide for determining pump volumetricefficiency which is the arithmetic average of the volumetric efficiencyof the individual pump chambers as determined by the onset of pressurerise as a function of crankshaft position (delay in suction valveclosing and seating) and the delay in pressure drop after a piston hasreached top dead center (delay in discharge valve closing and seating).

Additional parameters which may be measured and calculated in accordancewith the invention are the so-called delta volumes for the suction orinlet stabilizer and the discharge pulsation dampener. The delta volumeis the volume of fluid that must be stored and then returned to thefluid flowstream to make the pump suction and discharge fluid flow ratesubstantially constant. This volume varies as certain pump operatingparameters change. A significant increase in delta volume occurs whentiming delays are introduced in the opening and closing of the suctionand discharge valves. The delta volume is determined by applying actualangular degrees of rotation of the crankshaft with respect the suctionand discharge valve closure delays to a mathematical model thatintegrates the difference between the actual fluid flow rate and theaverage flow rate.

Another parameter associated with determining component life for a pump,is pump hydraulic power output for each pump working cycle or 360degrees of rotation of the crankshaft. Still further, pump componentlife cycles may be determined by using a multiple regression analysis todetermine parameters which can project the actual lives of pumpcomponents. The factors which affect life of pump components areabsolute maximum pressure, average maximum pressure, maximum pressurevariation and frequency, pump speed, fluid temperature, fluid lubricityand fluid abrasivity.

As mentioned previously, pressure variation during fluid “compression”is an indication of the condition of a piston or plunger packing seal.This variation is defined as an absolute maximum deviation of actualpressure data from a linear value representative of the compressionpressure and is an indication of the condition of seals. A leaking sealresults in a longer compression cycle because part of the fluid beingdisplaced is bypassing or leaking through the seal. A pump chamber“decompression” cycle is also shorter because, after the discharge valvecompletely closes and seals against its seat, part of the fluid to bedecompressed is bypassing a plunger seal or packing. The difference involume required to reach discharge operating pressure over a“compression” cycle for each pump chamber determines an average leakagerate. This leakage rate is adjusted for a leak rate at dischargeoperating pressures by calculating a leak velocity based on standardorifice plate pressure drop calculations.

Suction valve leak rate results in a longer decompression cycle becausepart of the fluid being displaced by the pressurizing element isreturning to the pump inlet or suction fluid flowline. The difference involume required to reach discharge operating pressure over a compressioncycle determines an average leakage rate. This compression leak rate isthen adjusted for a leak rate at discharge operating pressures bycalculating a leak velocity based on standard orifice plate pressuredrop calculations. The leak rate is then applied to the duration of thedischarge valve open cycle. So-called pump intake or suctionacceleration head response is an indicator of the suction pipingconfiguration and operating conditions which meet the pump's demand forfluid. This is defined as the elapsed time between the suction valveopening and the first chamber or suction piping or manifold pressurepeak following the opening.

Still further, the system of the present invention is operable todetermine fluid cavitation which usually results in high pressure“spikes” occurring in the pumping chamber during the suction stroke.Generally, the highest pressure spikes occur at the first pressure spikefollowing the opening of a suction valve. Both minimum and maximumpressures are monitored to determine the extent and partial cause ofcavitation.

The system is also operable to provide signals indicating valve designand operating conditions which can result in excessive peak pressures inthe pumping chambers before the discharge valve opens, for example.These peaks or so-called overshoot pressures can result in prematurepump component failure and excessive hydraulic forces in the dischargepiping. For purposes of such analysis, the overshoot pressure is definedas peak chamber pressure minus the average discharge fluid pressure.

The system of the present invention is also operable to analyzeoperating conditions in the pump suction and discharge flow lines, suchas in the piping. A normally operating multiplex power pump will inducepressure variations at both one and two times the crankshaft speedmultiplied by the number of pump pistons. Flow induced pressurevariation is defined as the sum of the peak-to-peak pressure resultingfrom these two frequencies. Also, acceleration induced pressure spikesare created when the pump valves open and close. Acceleration pressurevariation for purposes of the methodology of the invention is defined asthe total peak-to-peak pressure variation.

Hydraulic resonance occurs when a piping system has a hydraulic resonantfrequency that is excited by forces induced by operation of a pump.Fluid hydraulic resonance is determined by analysis of the pressurewaves created by the pump to determine how close the pressure responsematches a true sine wave. The computer 450 is programmed to activate analarm when the flow induced pressure variation exceeds a predeterminedlimit. Alternatively the computer 450 monitoring software can beprogrammed to trigger the reset relief valve that is operably connectedand controlled by the processor.

Those skilled in the art will appreciate that the system, includingpressure sensors together with the reset relief valve and its associatedsensors provides information which may be used to analyze a substantialnumber of system operating conditions for a pump. The processor isadapted to provide a visual display 456 which may be displayed on themonitor, providing graphical display of pressure versus crankshaftposition for each cylinder chamber and other parameters.

The system's computer 450 controller, hard drive or other digitalstorage device and display 456 can be used for predictive analysis ofthe pump and component parts providing data to the operator to revealconditions and maintenance related required tasks including but notlimited to:

Hidden Failure—A functional failure whose effects are not apparent tothe operating crew under normal circumstances if the failure mode occurson its own.Lubrication Task—The periodic application of a lubricant to items thatrequire lubrication for proper operation or to prevent prematurefunctional failures.Non-significant Function (NSF)—A function whose failure will have noadverse safety, environmental, operational, or economic effects.On Condition Task—A periodic or continuous inspection designed to detecta potential failure condition and allow correction prior to functionalfailure.Other Action—A term used to indicate that some action (other than PM) iseither required or desired to most effectively deal with theconsequences of a failure mode.Potential Failure—A definable and detectable condition that indicatesthat a functional failure will occur.Preventive Maintenance (PM)—Actions performed prior to functionalfailure (multiple failures or demand requirements for hidden failures)to achieve the desired level of safety and reliability for an item.Servicing Task—The replenishment of consumable materials that aredepleted during normal operations.Severity Classification—A category assigned to a failure mode based onthe impacts of its potential effects.Significant Function (SF)—A function whose failure will have adverseeffect with regard to Safety, Environment, Operations, and Economics.

In conjunction with the pump, is a fully controlled and monitoredpressure relief valve that is situated to set off with excessive mudflow pressures. Turning now to FIG. 5, there is a partially explodedcross sectional view of a reset relief valve showing chamber 500 and influid communication therewith and pressure sensor assembly 502 of therelief valve. A break is shown in FIG. 5 between the upper and lowerportion of the valve where the pressure sensor assembly 502 is placedfor ease of illustration. Transducer 506 is positioned in a sealed ring504 that is in fluid communication with the hydraulic fluid that movesbetween chambers 500 and 512 during operation. On the bottom of ring 504are ports 514 that permit fluid flow from chamber 500 into the ringwhereby the transducer 506 can sense pressure in the fluid. Pressure issensed by the transducer 506 which is capable of sensing the pressure onthe fluid which in turn transmits that pressure reading to a gauge 516and electronically to a computer control system. Gauge 516 may be analogor digital depending on the application. As pressure is being monitoredand data points stored, the user is capable of controlling the valve andmaking sure its operation is within desired operating limits beforeduring and after the valve is activated. Further, the computerparameters can be set for high pressures to shut down the pump beforethe reset valve is set off.

By storing data on a recurring basis, the operator can design the systemwith greater degrees of control and can analyze the data associated withan activation of the valve to better utilize the valve and other pumpsin the system. Set screw 520 permits access to the system for bleedingoff pressure. Other ports are positioned around the pressure sensorassembly for insertion of oil or other hydraulic fluid.

One of the advantages of having a relief valve that is computermonitored and controlled is that upon set-off the operator obtainsvaluable real time information about the pump just prior to and duringset-off. The system is capable of storing data about the operation ofthe pump such as the time of set-off, the exact pressure that caused therelief valve to activate and speed and pressure associated with thepump.

The graphic display of the computer system may also show the dischargepressure parameters including discharge manifold pressure, totalpeak-to-peak pressure, flow induced peak-to-peak pressure, flow inducedpeak-to-peak pressure as a percent of average manifold pressure, theprimary (largest) peak-to-peak pressure which is occurring at aparticular frequency, the primary peak-to-peak pressure as a percent ofaverage manifold pressure.

The processor may show pressure variation versus pump speed asdetermined by the system based on measuring chamber pressure andcrankshaft position and speed.

The system may further display information showing crankshaft angleversus pump speed in strokes per minute showing discharge valve sealingdelays in degrees of crankshaft rotation from piston top dead center.Suction valve sealing delays, from piston bottom dead center, may alsobe indicated.

The system of the invention may also be adapted to provide graphicdisplays such as a diagram of pump discharge pressure versus crankshaftangle showing the variation in pump discharge piping pressure, as wellas the frequency and amplitude of pressure pulsations. Another displaywhich may be provided by the system comprises a diagram of pumpdischarge piping pressure as measured by a pressure sensor versus pumpspeed in piston strokes per minute as calculated by the system. Stillfurther, the system is operable to display fluid pressure conditions inthe pump suction manifold, such as the manifold or piping. The systemcould also aid in de-synchronizing multiple pumps to decrease pulsationon the piping system.

A typical installation of a system for temporary or permanentperformance monitoring and/or analysis requires that all of the pressuretransducers be preferably on the horizontal center line of the pumppiping or pump chambers, respectively, to minimize gas and sedimententrapment.

The system of the invention is also operable to determine pump pipinghydraulic resonance and mechanical frequencies excited by one or morepumps connected thereto for both fixed and variable speed pumps.Preferably, a test procedure would involve instrumenting the pump, whereplural pumps are used, that is furthest from the system dischargeflowline or manifold. A vibration sensor, could be located at theposition of the most noticeable piping vibration. The piping systemshould be configured for the desired flow path and all block valves topumps not being operated should be open as though they were going to beoperating. The instrumented pump or pumps should be started and run atmaximum speed for fifteen minutes to allow stabilization of the system.A data acquisition system should then be operated to collect one minuteof pumping system data. Alternatively, data may be continued to becollected while changing pump speed at increments of five strokes perminute every thirty seconds until minimum operating speed is reached.Data may be continued to be collected while changing suction ordischarge pressures. The displays provided by the processor could bereviewed for pump operating problems as well as hydraulic and mechanicalresonance. If a hydraulic resonant condition is observed, this mayrequire the installation of wave blockers or orifice plates in thesystem piping.

The system is operable to provide displays comprising simulated threedimensional charts displaying peak-to-peak pressures occurring atrespective frequencies for a given pump speed in strokes per minute. Fora triplex pump, the normal excitation frequency is three and six timesthe pump speed. As pump speed increases, the excitation frequenciesincrease.

The software developed for the pump and valve is a method of acquiringmultiple streams of analog data as real time occurrences andsimultaneously displaying and storing them via digital interface usingan interface system for later analysis. Using an application developedfor this system, the control computer can monitor and record from 1 to 4simultaneous analog pressure readings at a rate of 1 sample/sec perchannel or faster. In addition a secondary capacity to monitor 4 digitalonly inputs is extant in the current system, with desired inputsundetermined. The data acquisition and its interaction and use with thesoftware acts as a control system to the overall pump and its variousoperating components and attachments.

The computer system of a preferred embodiment may be of any of a varietyof known systems with associated input and output devices, havingadequate processing speed and storage capacity to analyze and processdata associated with the operation of the pump. The system may also havewireless capability and preferably is capable of operating intemperature ranges of: 0 to 40° C.; Storage: −20 to 65° C., withRelative Humidity: 30% to 80%. It may use data processing of

-   -   4 channels of 14-bit analog input    -   Up to 200 kS/s single-channel sampling    -   Up to 132 kS/s multichannel (aggregate) sampling    -   4 digital I/O lines (3.3 V) Further, a variety of sensors may be        employed including preferably pressure transducers, with        0-10,000 PSI pressure sensitivity, 6-30 vdc input excitation        voltage, 1-5 vdc output signal, and simple 3 wire connections        (plus ground).

The software application employed preferably is a data acquisition andstorage system with a 90 day continuous storage capacity. The computersoftware permits real time evaluation of ambient pressure in the systemand control of the valve according to the user's preferences. Due to therecurrent sensing of the system, when the valve is set off, data hasbeen stored for later analysis of the cause of the pressure spike thatmay have set off the valve.

The present invention combines a computer controlled monitoring systemfor a pump and a reset relief valve with increased power characteristicsand longevity by use of poly-fluorocarbon treated or infused materialsand an integrally forged crank. By having the pump responsive to ambientconditions that are monitored real time, the reset valve, which isinterconnected through sensors that sense operating conditions of thepump system, can send feedback to the motor to reduce pressure buildupbefore the valve is set off. Further, in certain conditions the resetvalve can trip in advance of catastrophic failure of the pump throughthe computer control and feedback system of the present invention.

While the invention has been described in connection with a preferredembodiment, it is not intended to limit the scope of the invention tothe particular form set forth, but on the contrary, it is intended tocover such alternatives, modifications, and equivalents as may beincluded within the spirit and scope of the invention as defined by theclaims.

1. A pump system for movement of fluids comprising: A reciprocatingpiston power pump having at least three reciprocating pistons operableto displace fluid from a housing having a pumping chamber; An integrallyforged crankshaft operably connected to said pistons; At least onesensor operable to sense ambient conditions on said pump; and A computercontrol for processing data from said sensor to regulate the operationof the pump in response to said data.
 2. A pump system as claimed inclaim 1 further comprising a reset relief valve operably connected tosaid pump and actuatable in response to a predetermined pressure.
 3. Apump system as claimed in claim 1 further comprising a reset reliefvalve operably connected to said pump actuatable in response to a sensorin communication with said control.
 4. A pump system as claimed in claim1 further comprising sensing of conditions by a transducer.
 5. A pumpsystem as claimed in claim 1 wherein said pump speed may be operablycontrolled in response to said data.
 6. A pump system as claimed inclaim 3 wherein said pump speed may be operably controlled in responseto said transducer.
 7. A pump system as claimed in claim 1 furthercomprising a vessel for collecting pumped fluid before porting to adownstream pipe.
 8. A pump system for movement of fluids comprising: Areciprocating piston power pump having at least three reciprocatingpistons operable to displace fluid from a housing having a pumpingchamber; An integrally forged crankshaft operably connected to saidpistons; Polyflorocarbon infused treatment applied to at least onecrosshead slide in said system; and At least one sensor operable tosense ambient conditions on said pump.
 9. A pump system as claimed inclaim 8 further comprising an air pressure seal about a portion of a rodconnected to at least one of said pistons.
 10. A pump system as claimedin claim 8 further comprising an oil lubrication shower about saidcrankshaft.
 11. A pump system as claimed in claim 8 further comprising avibration sensor.
 12. A pump system as claimed in claim 8 wherein saidair pressure seal circumferentially applies pressurized air about saidrod.
 13. A pump system for movement of fluids comprising: Areciprocating piston power pump having at least three reciprocatingpistons operable to displace fluid from a housing having a pumpingchamber; An integrally forged crankshaft operably connected to saidpistons; At least one sensor operable to sense ambient conditions onsaid pump; A computer control for processing data from said sensor toregulate the operation of the pump in response to said data; andPressure sensors for monitoring fluid pressure operably connected tosaid computer control.
 14. A pump system as claimed in claim 12 furthercomprising a reset relief valve.
 15. A pump system as claimed in claim15 further comprising a vessel for receiving pumped fluid before portingto a pipe.